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IM529-A
® ®
October, 1999
CLASSIC III & CLASSIC III D
For Machines with Code Numbers 10033, 10061, 10072 or 10156
Supersedes IM482
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation ... and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
bef
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 General Description..............................................................................................................A-2 Design Features .....................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – CLASSIC III AND IIID Machine DC Current Range Product Ordering Description Rated DC Output * Auxiliary Dimensions (Fine Adjustment in Each Range) Name Information Amps / Volts / Duty Cycle Power & Weight 3000 Watts, 40 - 350 Amps 40.94 x 24.0 x 66.25in Classic III K1428-2 60 Hz. AC @ CSA (1040 x 610 x 1683 mm) w/o Wire Feed Module 220 - Max 26 Amps @ 1406 lbs (638 kg) 160 - 240 115V K1428-3 120 - 190 @ CSA 300 Amp DC 80 - 130 13 Amps @ w/ Wire Fee
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A-2 A-2 INSTALLATION DESIGN FEATURES GENERAL DESCRIPTION Control Panel ® ® The Classic III and Classic III D are heavy duty, Both the engine and the welder controls are located engine driven, DC arc welding power sources capable on one recessed panel at the exciter end of the of providing constant current output for stick welding machine. The welder controls consist of a five step or DC TIG welding. These welders are wound with all “Current Range Selector” switch and a “Fine Current copper coi
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A-3 A-3 INSTALLATION STACKING PRE-OPERATION INSTALLATION WARNING Classic III and III D machines cannot be stacked. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s ANGLE OF OPERATION manual supplied with your welder. It includes important safety precautions, detailed engine To achieve optimum engine performance the Classic starting, operating and maintenance instructions, III and III D should be run in a level position. The max- and parts lists. imum
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A-4 A-4 INSTALLATION Lift Bail Polarity Control and Cable Sizes A lift bail is provided for lifting with a hoist. With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank WARNING mounting rail. (See size recommendations below.) FALLING EQUIPMENT can cause For positive polarity, connect the electrode cable to injury. the terminal marked “+”. For Negative polarity, con- � Do not lift this machine u
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A-5 A-5 INSTALLATION Battery Charging PRE-OPERATION SERVICE WARNING CAUTION GASES FROM BATTERY can explode. READ the engine operating and maintenance instruc- � Keep sparks, flame and cigarettes tions supplied with this machine. away. WARNING BATTERY ACID can burn eyes and skin. can cause fire or explosion. Fuel � Wear gloves and eye protection and - be careful when boosting, charging or working near battery. � Stop engine while fueling. � Do not smoke when fueling. To prevent EXPLOSION when:
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B-1 B-1 OPERATION ENGINE OPERATION Starting the Classic III D Continental TMD27 WARNING Diesel Engine Do not attempt to use this equipment until you 1. Turn the Idler control switch to “High”. have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes 2. Turn the Ignition control switch to “On”. important safety precautions, detailed engine 3. Push the reset button. starting, operating and maintenance instructions, 4. Press the Glow Plug button for 10 to 20 seco
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B-2 B-2 OPERATION Range Selector” to the 190-120 position and then WELDER OPERATION adjust the “Fine Current Adjustment” for 175 amps. WARNING When a forceful “digging” arc is required, usually for vertical and overhead welding, use a higher “Current ELECTRIC SHOCK can kill. Range Selector” setting and lower open circuit volt- � Do not touch electrically live parts or age. For example: to obtain 175 amps and a forceful electrode with skin or wet clothing. arc, set the “Current Range Selector”
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B-3 B-3 OPERATION Auxiliary Power ------------------------------------------------------------------------ MOVING PARTS can injure. The AC auxiliary power, supplied as a standard, has a � Keep guards in place. rating of 3.0 kVA of 115/230 VAC (60 hertz). � Keep away from moving parts. � Only qualified personnel should With the 3.0 kVA, 115/230 VAC auxiliary power, one install, use or service this equipment. 115V duplex and one 230V grounding type receptacle are provided. The circuit is protecte
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B-4 B-4 OPERATION IMPORTANT: 1/2” clearance between the FLEXIBLE HOSE and the fuel tank edge is required. Also 2” clearance between FLEXIBLE HOSE and roof. 4. Reconnect negative battery cable. FIGURE 2 C B A A. FLEXIBLE HOSE B. HEAT COLLECTOR SHIELD C. AIR FILTER NOTE: On welders received directly from the factory, the “Deicing” kit is configured for “summer Seasons” CLASSIC III AND IIID
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C-1 C-1 ACCESSORIES OPTIONAL FEATURES (Field Installed) Wire Feed Module (K623-1) - Provides constant Accessory Set (K703) - Includes electrode and work voltage (CV) output with improved arc stability for cables, headshield, work clamp and electrode holder. Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P ™ Hi-Freq (K799) - Provides high frequency plus gas and LN-25. (Factory installed on the K1428-3 and valve for DC TIG welding. K1433-2). Linc-Thaw™
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D-1 D-1 MAINTENANCE 4. When necessary, remove the sediment bowl, if so MAINTENANCE equipped, from beneath the fuel tank and clean out any accumulated dirt and water. WARNING Have qualified personnel do the maintenance 5. Follow the engine service schedule in this manual work. Turn the engine off before working inside and the detailed maintenance and troubleshooting in the machine. In some cases, it may be neces- the engine manufacturer’s manual. sary to remove safety guards to perform required
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D-2 D-2 MAINTENANCE Replace brushes when they wear within 1/4” of the Nameplates pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face Whenever routine maintenance is performed on this to fit the commutator. Have an experienced mainte- machine - or at least yearly - inspect all nameplates nance man seat these brushes by lightly stoning the and labels for legibility. Replace those which are no commutator as the armature rotates at full speed
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D-3 D-3 MAINTENANCE ENGINE SERVICE Hours Between Servicing Maintenance Item Type or Capacity Daily 50 250 500 I Engine Oil (1) R Engine Oil (1) 7 qts (Including Filter) R Oil Filter Fram #PH-8A Purolator #PER-1A I Air Cleaner C Air Cleaner R Air Cleaner Cartridge Donaldson #P181050 Nelson #70206N C PCV System I Fan Belt Tension C Throttle or Governor Linkage C or R Spark Plugs (Gap=.032”) (4) Champion #RN12YC I Cooling System C Cooling System 9.3 qts R Fuel Filter (4) Lincoln #S17753 (2) R
